Brake fluid keeps leaking from reservoir - ZX6R Forum
 
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post #1 of 15 Old 06-12-2018, 10:25 AM Thread Starter
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Brake fluid keeps leaking from reservoir

I've got a 2003 zx6r with around 39000 miles on it. I flushed the front brakes a while ago and noticed there was some fluid leaking from the bottom of the reservoir where it connects to the tube to the MC. I went ahead and got one of those ebay special brake fluid reservoirs https://www.ebay.com/itm/Universal-B...ZCisHUWohEE2zw for my bike since the old one had some slight spider cracking and was due for a change anyways. After changing the reservoir, there is still brake fluid leaking from the bottom of the reservoir. Ive tried everything from getting new hose clamps, trying new brake hose tubing, getting another reservoir just in case the one i got was bad, going back to the oem one, and even used this https://www.amazon.com/XFasten-Water...eal+tape&psc=1 stuff to try and contain the leak. Brake fluid is STILL leaking from the reservoir. Does anyone know what would cause this to happen?
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post #2 of 15 Old 06-12-2018, 11:29 AM
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Is the leak because you have over filled the reservoir? Fill it just above the 'low' line, and see what happens.

If not, is it due to something at the MC end of that line?

"Basic stuff fellas. Use your head for something other than to break your next fall."
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post #3 of 15 Old 06-12-2018, 12:34 PM
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What are you using for hose to connect the res to the master?

Tygon is best and wonít weep, assuming thatís your problem. There are two diameters available depending on your application.

https://www.kurveygirl.com/shop/prod...aurtajrvkve2l4

Last edited by Duc995; 06-12-2018 at 01:57 PM.
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post #4 of 15 Old 06-12-2018, 02:46 PM Thread Starter
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Originally Posted by Duc995 View Post
What are you using for hose to connect the res to the master?

Tygon is best and won’t weep, assuming that’s your problem. There are two diameters available depending on your application.

https://www.kurveygirl.com/shop/prod...aurtajrvkve2l4
Yeah im using the tygon clear brake hose with the correct diameter for my MC and resevoir
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post #5 of 15 Old 06-12-2018, 02:50 PM Thread Starter
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Originally Posted by RJ2112 View Post
Is the leak because you have over filled the reservoir? Fill it just above the 'low' line, and see what happens.

If not, is it due to something at the MC end of that line?
I made sure to nearly underfill the reservoir multiple times at different levels. It still leaks at the correct level/ low level/ high level. Ive gone through so much brake fluid while testing it. Luckily brake fluid is pretty cheap. I have no idea what could possibly cause
this.
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post #6 of 15 Old 06-12-2018, 03:29 PM
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Have you done anything with the brake lines?

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post #7 of 15 Old 06-12-2018, 06:11 PM Thread Starter
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Have you done anything with the brake lines?
Nope. Havent even touched them.
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post #8 of 15 Old 06-13-2018, 01:10 AM
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I'm stuck with thinking that the problem is not the reservoir... Too many exchanges without a change in the problem. From there, lines or MC seem to be the only options.

Any corrosion, pitting, cracking? Has a rebuild been done?

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post #9 of 15 Old 06-13-2018, 01:27 AM
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Keep pumping the shit out of the brakes until u see where its leaking from.
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post #10 of 15 Old 06-13-2018, 05:23 AM
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Are you sure something else is not going on. What you are describing sounds literally impossible. Are you sure you are cleaning your work after your installs, are you sure that your bike is not parked in a chalk at the same exact spot and you have a roof leak or something, are you sure you're not constantly using the wrong tube size?
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post #11 of 15 Old 06-14-2018, 12:59 PM Thread Starter
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Originally Posted by Sabotage View Post
Are you sure something else is not going on. What you are describing sounds literally impossible. Are you sure you are cleaning your work after your installs, are you sure that your bike is not parked in a chalk at the same exact spot and you have a roof leak or something, are you sure you're not constantly using the wrong tube size?
Yes i clean my work thoroughly to check for future leaks. I am sure it is not a roof leak unless brake fluid leaks from the roof causing the paint to strip on my triple clamp. I used the correct tube size from tygon which is 8mm inner diameter.
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post #12 of 15 Old 06-14-2018, 01:06 PM Thread Starter
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Originally Posted by RJ2112 View Post
I'm stuck with thinking that the problem is not the reservoir... Too many exchanges without a change in the problem. From there, lines or MC seem to be the only options.

Any corrosion, pitting, cracking? Has a rebuild been done?
I did notice some rusting on the steel braided brake lines where it connects to the caliper. And the only cracking i noticed was from the previous oem brake reservoir which is why i changed it out for the cnc aluminum one. I also dont see any imperfections on the MC or any other imperfections on the brake lines besides where it connects to the caliper. There's no leaking where the line is rusty at the caliper.
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post #13 of 15 Old 06-14-2018, 01:13 PM Thread Starter
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Ok so i ordered these hose clamps https://www.amazon.com/Hilitchi-Adju...ds=hose+clamps because it seems like the oem ones just arent strong enough to make a good enough seal around the brake reservoir connection. I cranked the clamp on REALLY tight to the reservoir and it seems to not be leaking as of yet. Even if this does fix the problem permanently, shouldn't the oem hose clamps be plenty strong enough to prevent leaking from the reservoir? I guess i just find it strange that kawasaki would use those weak pinch clamps instead of these worm gear clamps in the first place like they do for the radiator hoses.
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post #14 of 15 Old 06-14-2018, 03:11 PM
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Quote:
Originally Posted by kwakamole View Post
Ok so i ordered these hose clamps https://www.amazon.com/Hilitchi-Adju...ds=hose+clamps because it seems like the oem ones just arent strong enough to make a good enough seal around the brake reservoir connection. I cranked the clamp on REALLY tight to the reservoir and it seems to not be leaking as of yet. Even if this does fix the problem permanently, shouldn't the oem hose clamps be plenty strong enough to prevent leaking from the reservoir? I guess i just find it strange that kawasaki would use those weak pinch clamps instead of these worm gear clamps in the first place like they do for the radiator hoses.
My clamps are pretty strong. Maybe you have stretched yours out too much and caused it to lose its strength?
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post #15 of 15 Old 06-14-2018, 06:27 PM Thread Starter
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Originally Posted by Scorpi0 View Post
Quote:
Originally Posted by kwakamole View Post
Ok so i ordered these hose clamps https://www.amazon.com/Hilitchi-Adju...ds=hose+clamps because it seems like the oem ones just arent strong enough to make a good enough seal around the brake reservoir connection. I cranked the clamp on REALLY tight to the reservoir and it seems to not be leaking as of yet. Even if this does fix the problem permanently, shouldn't the oem hose clamps be plenty strong enough to prevent leaking from the reservoir? I guess i just find it strange that kawasaki would use those weak pinch clamps instead of these worm gear clamps in the first place like they do for the radiator hoses.
My clamps are pretty strong. Maybe you have stretched yours out too much and caused it to lose its strength?
I ordered brand new ones with the same diameter. Idk my problem is fixed for now but im just worried that down the road it might show up again
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